Adhesive-Free Bonded Balloon for a Balloon Guide Catheter With Minimal Outer Profile

ABSTRACT

A balloon guide catheter with a catheter shaft having an outer layer made of a reflowable material and a balloon having a bond interface area with a plurality of punctures defined therein secured about the outer layer of the catheter shaft via seepage of the reflowable material of the outer layer into the plurality of punctures forming a radially outward reflow bond between the catheter shaft and the balloon without the use of an adhesive. One or more reflow jackets made of a reflowable material may also be disposed about the bond interface area of the balloon seeping into the plural punctures forming a radially inward reflow bond.

BACKGROUND OF THE INVENTION Field of the Invention

During capture and retrieval of a thrombus, occlusion, or clot in a vessel using an intravascular catheter with a compliant inflatable balloon may be employed to arrest blood flow. The balloon and exterior surface of the catheter shaft of the present inventive balloon guide catheter are secured together at an adhesive free bonding interface area(s) thereby minimizing the outer profile/diameter while optimizing bond strength.

Description of Related Art

Acute ischemic stroke is primarily caused by a thrombotic or embolic occlusion (e.g., blockage) in an artery of the brain. The occlusion is typically caused by a blood clot liberated from another part of the body which travels in an antegrade direction (in the direction of normal blood flow) through the vessel and eventually becomes lodged in a neurovascular artery, where it obstructs blood flow to a region of the brain.

A procedure known as a thrombectomy may be used to remove the thrombus, occlusion, blockage or clot lodged in the vessel using a mechanical retrieval device. During the thrombectomy procedure or treatment a physician or interventionalist endovascularly introduces a guidewire and microcatheter together through the vasculature, typically in an artery located in the groin or the arm or by direct access through the carotid artery. Together the guidewire and microcatheter are advanced to a location facing a proximal side of the targeted clot, blockage or occlusion. Then the guidewire is advanced across the clot, followed by the microcatheter. While in a compressed state, a mechanical thrombectomy device may be guided through the lumen of the microcatheter to the target site. Upon emerging from the microcatheter the mechanical thrombectomy device typically automatically expands to its original enlarged state. Mechanical thrombectomy devices are typically made of a self-expanding biocompatible material such as nickel-titanium. Aspiration through the catheter may accompany or be used in place of the mechanical retrieval device to remove the clot.

During a thrombectomy procedure balloon guide catheters are often employed to arrest blood flow by introducing an inflation fluid into a compliant inflatable balloon. Bonding of the compliant inflatable balloon to the exterior surface of the catheter shaft during manufacture of the balloon guide catheter has two competing criteria, i.e., minimization of the outer profile/diameter at the bonding interface area in which the balloon is mounted to the catheter shaft while maximizing bond strength and integrity.

It is desirable to design an improved balloon guide catheter having an adhesive free bond interface area where the balloon (e.g., compliant, semi-compliant, or non-compliant) is secured to the exterior surface of the catheter shaft to achieve optimum bond strength and integrity while minimizing outer profile or outer diameter.

SUMMARY OF THE INVENTION

An aspect of the present invention is directed to an improved balloon guide catheter to which a balloon is bonded thereto without the use of an adhesive producing maximized bonding strength and integrity while minimizing outer profile or outer diameter.

Another aspect of the present invention is directed to a balloon guide catheter with a catheter shaft having an outer layer made of a reflowable material and a balloon having a bond interface area with a plurality of punctures defined therein secured about the outer layer of the catheter shaft via seepage of the reflowable material of the outer layer into the plurality of punctures forming a radially outward reflow bond between the catheter shaft and the balloon. The balloon being securable to the catheter shaft without the use of an adhesive.

Still another aspect of the present invention is directed to a method for assembling a balloon guide catheter. A plurality of punctures is pierced in a bond interface area of a balloon where securable to an outer layer made of a reflowable material of a catheter shaft. The balloon with the plurality of punctures pierced therein is arranged about the outer layer of the catheter shaft. Along the bond interface area, the reflowable material of the outer layer of the catheter shaft is subject to heat causing it to seep into the plurality of punctures creating a radially outward reflow bond between the outer layer of the catheter shaft and the balloon. Thus, the balloon is securable to the catheter shaft without the use of an adhesive.

BRIEF DESCRIPTION OF THE DRAWING

The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings illustrative of the invention wherein like reference numbers refer to similar elements throughout the several views and in which:

FIG. 1 is a side view of an exemplary compliant inflatable balloon in accordance with the present invention prior to being assembled about a catheter shaft, wherein the compliant inflatable balloon has a proximal bond interface area and an opposite distal bond interface area, each bond interface area having a plurality of puncture holes defined therethrough;

FIG. 2A is a partial side view of an assembled balloon guide catheter including the compliant inflatable balloon of FIG. 1 and a catheter shaft having an outer layer of reflow material reflowing into the plurality of puncture holes defined in the compliant inflatable balloon forming a radially outward reflow bond, wherein the compliant inflatable balloon is depicted in a non-inflated state;

FIG. 2B is a longitudinal cross-sectional view of the assembled balloon guide catheter of FIG. 2A illustrating the radially outward reflow bond formed by seepage of the outer layer of reflow material into the plurality of puncture holes defined in the compliant inflatable balloon;

FIG. 3 is a radial cross-sectional view of an outer layer of the catheter shaft in FIG. 2A;

FIG. 4A is a partial longitudinal cross-sectional view of an alternative configuration with two reflow jackets/sleeves separate from one another in an axial direction to form a 360° radial gap therebetween, each reflow jacket/sleeve securing beneath a respective proximal and distal bond interface area of the compliant inflatable balloon to the outer layer of the catheter shaft, wherein the compliant inflatable balloon is represented in a non-inflated state;

FIG. 4B is a side view of the assembled catheter of FIG. 4A;

FIG. 5A is a partial longitudinal cross-sectional view of still another design with a single reflow jacket/sleeve having a cut-out or opening defined therein aligned with a compliant inflatable balloon patch secured beneath to the catheter shaft, wherein the compliant inflatable balloon is depicted in a non-inflated state; and

FIG. 5B is a top view of the assembled catheter of FIG. 5A.

DETAILED DESCRIPTION OF THE INVENTION

The terms “distal” or “proximal” are used in the following description with respect to a position or direction relative to the treating physician or medical interventionalist. “Distal” or “distally” are a position distant from or in a direction away from the physician or interventionalist. “Proximal” or “proximally” or “proximate” are a position near or in a direction toward the physician or medical interventionalist. The terms “occlusion”, “clot” or “blockage” are used interchangeably.

Balloons are typically adhered via adhesive to the exterior surface of the catheter shaft of an assembled balloon guide catheter. The use of an adhesive for securing the balloon poses several disadvantages: increased bond profile and difficulty controlling/constraining the boundaries in which the adhesive remains. It is therefore an aspect of the present invention to eliminate the use of the adhesive (adhesive free bond or non-adhesive bond) where the compliant inflatable balloon is secured to the outer layer of the catheter shaft without sacrificing bond integrity or strength.

During a thrombectomy procedure balloon guide catheters are often employed to arrest blood flow by introducing an inflation fluid into a compliant inflatable balloon (rather than inflating via pressure) made of an elastomeric material, for example, polyurethane, polyblend, or latex. Its ability to conform to the shape of the vasculature makes the compliant inflatable balloon particularly suited for use in arresting of blood flow. In other applications such as dilating of a vessel or opening an occlusion, balloon guide catheters may employ a non-compliant or semi-compliant balloon that is inflated by pressure, rather than using an inflation fluid. Specifically, non-compliant balloons typically made of polyester or nylon when inflated at a high pressure dilate a vessel or open an occlusion; whereas semi-compliant balloons made of material such as Pebax or higher durometer polyurethanes when inflated in pressure are more compliant than that of non-compliant balloons providing greater flexibility during delivery. Regardless of the type of balloon (compliant, semi-compliant, or non-compliant), bonding of the balloon to the exterior surface of the catheter shaft during manufacture has two competing criteria, i.e., minimization of the outer profile/diameter at the bonding interface area(s) in which the balloon is mounted to the catheter shaft while maximizing bond strength and integrity. By way of example, the present inventive balloon guide catheter is illustrated and described using a compliant inflatable balloon for arresting blood flow through the vessel. It is understood that the present invention is applicable for use with any type of balloon (e.g., compliant, semi-compliant, or non-compliant). FIG. 1 is a side view of a compliant inflatable balloon sleeve 105 in accordance with the present invention prior to assembly about a catheter shaft. Compliant inflatable balloon 105 has a proximal bond interface area 110 and an opposite distal bond interface area 115, wherein the compliant inflatable balloon 105 is securable about the catheter shaft 125 along the proximal and bond interface areas 110, 115, respectively. Each of the proximal and distal bond interface areas has a plurality of punctures 120 (e.g., piercings, holes or openings) therethrough made, for example, with a fine punch tool or other mechanical device. The axial length of each of the proximal and distal bond interface areas 110, 115 with the plural punctures defined therein is preferably approximately 2 mm—approximately 3 mm.

The compliant inflatable balloon 105 with the plural punctures 120 made in each of the proximal and distal bond interface areas 110, 115, respectively, is positioned exteriorly about a catheter shaft 125 as shown in FIGS. 2A & 2B. A radial cross-sectional view through an exemplary catheter shaft 125 illustrating its outer layer 130 is represented in FIG. 3. The outer layer 130 of the catheter shaft is made of a reflowable material, preferably one that includes medical grade thermoplastic polyurethane (TPU) (e.g., Tecoflex®—a medical-grade Aliphatic Polyether-based Thermoplastic Polyurethane). Catheter shaft 125 may be designed, as desired, to comprise any number of one or more inner layers disposed radially inward of the outer layer130.

Specific regions of the compliant inflatable balloon 105, preferably restricted only to those areas to be bonded to the catheter shaft (e.g., proximal and distal bond interface areas 110, 115 of the balloon sleeve; or a perimeter of a balloon patch), are subject to heat (e.g., thermal and/or laser generated) causing reflow/melting of the outer layer 130 of the catheter shaft 125 which seeps/oozes upwards through the punctures 120 (piercings, holes, openings) forming a radially outward reflow bond therebetween. By way of illustrative example, heated jaws may be applied only about those areas of the compliant inflatable balloon to be bonded thereby restricting the heat to a certain area or distance.

To further strengthen the bond of the balloon to the catheter shaft, an additional step may be performed in sequence or simultaneously with the forming of the radially outward reflow bond to create a supplemental radially inward reflow bond using one or more reflow jacket(s)/sleeve(s) made of a reflow material (a material that preferably includes medical grade thermoplastic polyurethane (TPU)). Preferably, the reflow material of the one or more reflow jacket(s)/sleeve(s) and that of the outer layer of the catheter shaft is the same to ensure the reflow of both materials when subject to heat at a predetermined temperature. Thus, the reflow bond is created both radially inward and radially outward of the proximal and distal interface bond areas of the compliant inflatable balloon. That is, when heated the reflow/melted outer layer 130 of the catheter shaft 125 seeps radially outwards through the punctures 120 creating a radially outward reflow bond, while the reflow/melted reflow jackets/sleeves 135, 140 ooze radially inwards through the punctures 120 creating a radially inward reflow bond. The enhanced reflow bonds (radially inward and radially outward) created between the reflowing/melting of the material for the reflow jackets/sleeves 135, 140 and outer layer 130 of the catheter shaft 125 into the punctures 120 on either side of the compliant inflatable balloon 105 optimizes bond integrity and strength while minimizing the potential for leakage without increasing the outer diameter/profile.

In one configuration shown in FIGS. 4A & 4B, two reflow jackets/sleeves are employed, i.e., one reflow jacket/sleeve placed about each of the proximal and distal bond interface areas 110, 115 of the compliant inflatable balloon sleeve 105. That is, a proximal reflow jacket/sleeve 135 is disposed about the compliant inflatable balloon coinciding with/covering the proximal bond interface area 110, while a distal reflow jacket/sleeve 140 is positioned about the compliant inflatable balloon coinciding with/covering the distal bond interface area 115. Dashed lines in the side view of FIG. 4B depict the proximal and distal edges 109, 114, respectively, of the compliant inflatable balloon 105 covered by the respective proximal and distal reflow jackets/sleeves 135, 140. A 360° radial gap 145 is formed between proximal and distal reflow jackets/sleeves 135, 140 separated in an axial/longitudinal direction from one another. Preferably, the two reflow jackets/sleeves are each made of the same material as that of the outer layer 130 of the catheter shaft 125 to ensure reflow when heated at a predetermined temperature. When inflated with an inflation fluid, the exposed 360° radial region of the compliant inflatable balloon patch 105 expands through the 360° radial gap 145 forming a radial bulge or radial inflation (e.g., tire).

An alternative design employing a single reflow jacket/sleeve 137 with a cut-out or opening 138 defined therein is set forth in the longitudinal cross-sectional and top views of FIGS. 5A and 5B, respectively. In this configuration since a single reflow jacket/sleeve 137 is used, the cut-out or opening 138 defined in the axial/longitudinal side thereof extends less than 360° radially. The dimensions (both axially/longitudinally and radially/laterally) of the cut-out or opening 138 is slightly smaller than a perimeter of the compliant inflatable balloon patch 105′. During assembly the single reflow jacket/sleeve 137 is aligned with and disposed radially outward of the compliant inflatable balloon patch 105′ exposing a central region of the compliant inflatable balloon patch 105′ through the cut-out or opening 138. When inflated with an inflation fluid, the exposed central region of the compliant inflatable balloon patch 105′ expands through the cut-out or opening 138 forming a side bulge or side inflation.

The different aspects, features, designs and configurations of the invention may be combined, as desired, for a given intravascular catheter with the intended goals of enhancing the integrity and strength of the bond between the balloon and the catheter shaft, while simultaneously minimizing the outer profile or outer diameter of the assembled catheter.

Thus, while there have been shown, described, and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions, substitutions, and changes in the form and details of the systems/devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit and scope of the invention. For example, it is expressly intended that all combinations of those elements and/or steps that perform substantially the same function, in substantially the same way, to achieve the same results be within the scope of the invention. Substitutions of elements from one described embodiment to another are also fully intended and contemplated. It is also to be understood that the drawings are not necessarily drawn to scale, but that they are merely conceptual in nature. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.

Every issued patent, pending patent application, publication, journal article, book or any other reference cited herein is each incorporated by reference in their entirety. 

What is claimed is:
 1. A balloon guide catheter comprising: a catheter shaft having an outer layer made of a reflowable material; and a balloon having a bond interface area with a plurality of punctures defined therein secured about the outer layer of the catheter shaft via seepage of the reflowable material of the outer layer into the plurality of punctures forming a radially outward reflow bond between the catheter shaft and the balloon; wherein the balloon is secured to the catheter shaft without an adhesive.
 2. The balloon guide catheter according to claim 1, wherein the reflowable material of the outer layer comprises a medical grade thermoplastic polyurethane.
 3. The balloon guide catheter according to claim 1, wherein the balloon is a sleeve and the bond interface area comprises a proximal bond interface area and an opposite distal bond interface area; wherein the plurality of punctures is arranged 360° radially in the proximal and distal bond interface areas of the balloon sleeve.
 4. The balloon guide catheter according to claim 3, each of the proximal and distal bond interface areas of the balloon sleeve having the plurality of punctures defined therein is approximately 2 mm in an axial direction.
 5. The balloon guide catheter according to claim 3, further comprising: a proximal reflow jacket disposed about the balloon covering the proximal bond interface area; and a distal reflow jacket disposed about the balloon covering the distal bond interface area; the distal reflow jacket being separated in an axial direction from the proximal reflow jacket forming a 360° radial gap therebetween through which a portion of the balloon is exposed; wherein each of the proximal and distal reflow jackets is made of a reflowable material; the proximal and distal reflow jackets being securable to the balloon via the reflowable material of the proximal and distal outer jackets seepable into the plural punctures forming a radially inward reflow bond; wherein the proximal and distal reflow jackets are secured to the balloon without an adhesive.
 6. The balloon guide catheter according to claim 5, wherein the reflowable material of the proximal and distal reflow jackets is the same as the reflowable material of the outer layer of the catheter shaft.
 7. The balloon guide catheter according to claim 1, wherein the balloon is a patch or a sleeve.
 8. The balloon guide catheter according to claim 7, further comprising: a single reflow jacket made of a reflowable material; the single reflow jacket having an opening defined therein aligned with the balloon; and wherein along the bond interface area about the perimeter of the opening in the balloon, the single reflow jacket is secured to the balloon via seepage of the reflowable material of the single reflow jacket into the plural punctures of the balloon forming a radially inward reflow bond.
 9. The balloon guide catheter according to claim 8, wherein the reflowable material of the single reflow jacket is the same as the reflowable material of the outer layer of the catheter shaft.
 10. A method for assembling a balloon guide catheter, the method comprising the steps of: piercing a plurality of punctures in a bond interface area of a balloon where securable to an outer layer made of a reflowable material of a catheter shaft; arranging the balloon with the plurality of punctures pierced therein about the outer layer of the catheter shaft; and subjecting to heat along the bond interface area causing the reflowable material of the outer layer of the catheter shaft to seep into the plurality of punctures creating a radially outward reflow bond between the outer layer of the catheter shaft and the balloon; wherein the balloon is secured to the catheter shaft without an adhesive.
 11. The method according to claim 10, wherein the reflowable material of the outer layer comprises a medical grade thermoplastic polyurethane.
 12. The method according to claim 10, wherein the balloon is a sleeve and the bond interface area comprises a proximal bond interface area and an opposite distal bond interface area; wherein the plurality of punctures is arranged 360° radially in the proximal and distal bond interface areas of the balloon sleeve.
 13. The method according to claim 12, wherein each of the proximal and distal bond interface areas of the balloon sleeve having the plurality of punctures defined therein is approximately 2 mm in an axial direction.
 14. The method according to claim 13, further comprising the step of: positioning a proximal reflow jacket disposed about the balloon covering the proximal bond interface area and a distal reflow jacket disposed about the balloon covering the distal bond interface area; wherein the distal reflow jacket is separated in an axial direction from the proximal reflow jacket forming a 360° radial gap therebetween through which a portion of the balloon is exposed; wherein each of the proximal and distal reflow jackets is made of a reflowable material; further securing the balloon to the outer layer of the catheter shaft by heating of the reflow material of the proximal and distal reflow jackets causing seepage into the plurality of punctures forming a radially inward reflow bond.
 15. The method according to claim 14, wherein the reflowable material of the proximal and distal reflow jackets is the same as the reflowable material of the outer layer of the catheter shaft.
 16. The method according to claim 15, further comprising the step of: positioning a single reflow jacket made of a reflowable material disposed about the balloon covering the bond interface area; the single reflow jacket having an opening defined therein aligned with the balloon; and wherein along the bond interface area about a perimeter of the opening in the balloon, securing the single reflow jacket to the balloon by heating of the reflowable material of the single reflow jacket causing seepage into the plural punctures of the balloon forming a radially inward reflow bond.
 17. The method according to claim 16, wherein the reflowable material of the single reflow jacket is the same as the reflowable material of the outer layer of the catheter shaft. 